"KW" Series Rotary Phase Converter

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Designed for world-wide use where the voltage input is 400-480VAC, 50Hz or 60Hz

Runs 3-Phase Equipment at FULL POWER from Single-Phase Power

The Rotary Converter is designed to supply full running current to a three-phase motor, normally providing it with full running torque. However, most motors will draw five times their running current during start-up. When sized KW for KW the Rotary Converter cannot deliver the full (5 times) starting current to the motor and therefore cannot provide full starting torque. You must always use a larger KW rated Rotary Converter than the KW rating of the motor. Please refer to the “KW” Rotary Converter Application Notes page, or form RTNKW.pdf.

Why buy the Phase-A-Matic, Inc. "KW" Rotary Phase Converter:

Reliability, quality and construction of the PHASE-A-MATIC™

Baldor Electric/PHASE-A-MATIC™ Design

The rotary portion of our converter is proprietary, custom built to our specifications by Baldor Electric, one of the largest and most trusted motor manufacturers in the world, with warranty stations nationwide and worldwide. It is a true phase converter and not a modified electric motor as most of our competitors use. Many years of testing, changing and developing the converter in conjunction with Baldor’s engineers has produced a very simple and trouble-free converter with extremely low idle current and low noise level. Many of our customers confirm that our rotary converters are the quietest and most trouble-free available.

Simplicity of design; uses all soldered connections

Keeping the design exceptionally simple reduces the risk of electrical connection failure to almost zero since these are some of the most common causes of failure. We use only soldered connections with no mechanical electrical connections like spade clips, terminals or screws which can vibrate loose or corrode over time. There are no start capacitors, relays or contactors with connections which can come loose or arc and weld the contacts causing failure of the contactor and the start capacitors, and perhaps even the rotary converter or your equipment. Because of this we do not have circuit board failures caused by spikes generated by the magnetic contactors as some of our competitors do.

The Rotor

The PHASE-A-MATIC™ failure rate is practically zero because the rotors are specifically designed and manufactured for rotary converter use. However, some of our competitors emphasize that rotors often fail. This is because they machine standard electric motors, modifying and thereby weakening standard electric motor rotors, which were not originally designed to be used as a phase converter.

Testing before shipment

Every converter is performance tested before shipment and assigned a serial number. These records are kept for review if any questions should ever arise about the performance specifications.

Warranty Repairs

The most likely warranty repair would be bearings or windings, which are very rare. This type of failure is much less than 1%, and if it is going to happen at all, most likely would occur within the first 12 months. Failures after that are extremely rare. See MTBF below.

MTBF (Mean Time Between Failure)

Failure rate (MTBF) is so low it's almost impossible to determine. We find that within the first 12 months approximately 1 in 150 might have a problem, and usually within a few weeks or months. After the first 12 months, it might be one or less in 5,000 over a 30 year period. We continue to hear of our Rotary Converters that have been in service for 25 or 30 years, and which are still working flawlessly. It could go on to do another 25 or 30 years. There is very little to go wrong with the Rotary Converter.

SIZING HELPS:

Refer to Application Notes - additionally available in PDF form as RTNKW.pdf. Help is also available through the Sizing Assistance page. Just fill out the appropriate form and submit it to us. A qualified technician from Phase-A-Matic, Inc. will contact you.

N/AThe Rotary Converter is designed to supply full running current to a three-phase motor, normally providing it with full running torque. However, most motors will draw five times their running current during start-up. When sized KW for KW the Rotary Converter cannot deliver the full (5 times) starting current to the motor and therefore cannot provide full starting torque. You must always use a larger KW rated Rotary Converter than the KW rating of the motor.

There is no minimum load requirement for the Rotary Converter. Some customers will install a Rotary Converter larger than needed to accommodate any future additions to their equipment. Below are the minimum size recommendations for various applications.

Sizing For Load Types

1. Motor Loads

TYPE 1 - American made motors:This load type applies to machinery with American made motors and which start with no load such as mills with step-pulley speed change, lathes with a clutch, sewing machines, and so forth. Use a converter with KW rating of at least 50% larger than the KW of the motor.*

Note: For instant reversing (as for rigid tapping), use a converter with twice the KW rating of the motor.

TYPE 2 - American and European made motors:Use a converter with a KW rating of at least 100% larger than KW of the motor (twice the rating). This load type includes American & European lathes without a clutch, some pumps, blowers, paper cutters, flywheel driven equipment, woodworking saws, dough mixers, meat grinders, motors rated below 1000 RPM, etc.

Note: For instant reversing (as for rigid tapping), use a converter with twice the KW rating of the motor.

TYPE 3 - Taiwanese, Chinese, & Mexican made, Design "E" motors and motors starting under load:This load type includes Design “E” motors, Taiwanese, Chinese, Mexican motors, machinery starting underload such as pumps, refrigeration compressors, etc., and for any motor which is used for instant reversing, as for rigid tapping. Use a converter with twice the KW rating of the motor.

TYPE 4 - Extreme start-up load:Extreme start-up loads include Brazilian made WEG motors, and machinery such as laundry extractors, hoists, elevators, etc. This type of equipment can be extremely heavily loaded on start-up. Use a converter with three times the KW rating of the motor. Consult Phase-A-Matic, Inc. for the possibility of successfully using a converter sized less than three times larger on these machines.

TYPE 5 - Hydraulic:Often hydraulic pumps, which come under a momentary load during use will be loaded well beyond the KW rating of the motor for the brief period of maximum PSI. Examples includes bailers, compactors, paper cutters, shears, pumps, etc. The KW rating of the converter must be at least as high as the actual KW developed by the motor during maximum compression. Size accordingly.

2. Resistive, Computer, Rectifier & Transformer Loads

Size a minimum KW of 50% larger.

3. Multiple Motor Applications

The Rotary Converter can run multiple loads simultaneously, but only within certain parameters. RESTRICTIONS APPLY! Contact Phase-A-Matic, Inc. for consultation.

Never connect a ground or neutral to line T-3 (manufactured phase), which can easily be identified as the line with the highest voltage to ground with the converter running.

It is essential that careful consideration be given to your wiring length and size to prevent slow starting due to a voltage drop. Consult Electrical Code for proper wire sizing.

Due to the high starting current (in-rush current) common to electric motors, a drop of starting torque may occur when using a converter that is too small. Because of this, it is NOT advised to size an application KW for KW. The vast majority of applications require sizing the converter 100% larger or more than the largest KW rated motor of your equipment. See Application Notes for sizing considerations, or call 1-800-962-6976.

The tables below show the approximate idle current at 415V. Higher line voltage will cause idle current to increase. Excessive amperage could also be caused by incorrect installation.

For converters with grease fittings, lubricate every 12 months for normal operation, or every 6 months for continuous (24 hour) operation. Use high temp bearing grease: “Exxon POLYREX®EM” polyurea grease or equivalent available from Phase-A-Matic, Inc.

Converters are intended for use in clean, dry locations with access to an adequate supply of cooling air. In addition, there should be protection from or avoidance of flammable or combustible materials in the area of converters as they can eject flame and/or metal in the event of an insulation failure.

"KW" series Rotary Converter is 400-480V single-phase in and 400-480V three-phase out, 50Hz and 60Hz use.

Largest Motor KW: Almost all machines require sizing the converter 100% larger or more than the largest KW motor rating of your machine. See paragraph #4 above. Also refer to Sizing for Load Types.

Minimum Single Phase Supply: Single-phase supply shown is for absolute maximum output of the Rotary Converter. Most of the time the converter is oversized to provide the high starting current for the motor. It is not always necessary to use single-phase breakers sized this large. Contact Phase-A-Matic, Inc. for smaller single-phase breaker qualifications.

IMPORTANT: This chart is simplified and cannot reflect the many types of applications possible. Contact Phase-A-Matic, Inc. at 1-800-962-6976 to verify your phase converter requirements. Also refer to Application Notes for sizing considerations.

Larger Horsepower phase converter systems may be obtained by connecting multiple Rotary Converters in parallel. This is necessary for output greater than 55 KW. Contact Phase-A-Matic, Inc. for help.

Installation Diagram

"KW" series Rotary Converter is 400-480V single-phase in and 400-480V three-phase out, 50Hz and 60Hz use.

Higher line voltages or voltage sensitive applications, such as CNC equipment, may require a Voltage Stabilizer.

Refer to Application Notes - additionally available in PDF form as RTNKW.pdf. Help is also available through the Sizing Assistance page. Just fill out the appropriate form and submit it to us. A qualified technician from Phase-A-Matic, Inc. will contact you.